Packaging material provided with cushioning members

ABSTRACT

To improve cushioning effect for a packaged object without causing cost increase and prevent positional shift of cushioning members without causing lowering of the strength and durability of a packaging box, a packaging material includes a packaging box and cushioning members, a bottom panel and a cover panel of the packaging box being made of inwardly bendable inner flaps and outer flaps respectively, each of the inner flaps being provided with at least a through hole, the cushioning members being provided in inner side surfaces thereof with recesses in which corner portions or side portions of an object to be packaged are fitted, and on outer side surfaces thereof with cushioning projections fitted in the through holes of the inner flaps, the length of the cushioning projections being set larger than the thickness of the inner flaps so as to form a clearance between the inner flaps and cushioning projections when the cushioning members are housed in the packaging box.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a packaging material including a packaging box used to package a product such as electrical equipment therein, and cushioning members arranged in the packaging box.

2. Related Art

A product, though it is not limited to electrical equipment, manufactured in a factory is packaged in a corrugated carton and shipped, and cushioning members for protecting the product against an impact imparted thereto during the transportation thereof are used in the packaging box. Especially, electrical equipment has a structure in which electronic parts and precise mechanical parts are combined together, so that the electrical equipment is easily affected by an impact. Therefore, cushioning members are necessary for and indispensable to the packaging of electrical equipment. There are various types of such cushioning member-carrying packaging boxes.

The “Packaging Box with Cushioning Member” disclosed in JP-A-7-242233 is capable of placing an product to be packaged, smoothly in a packaging box without positional shift of cushioning members, and provided on an internal surface of the packaging box with cut and raised parts so as to prevent the product from being taken out with the cushioning members left attached thereinto. Each of the cushioning members protecting lower edge parts of the packaged product is provided with an engaging part formed so that the engaging part is engaged with the relative cut and raised part when the relative cushioning member is slid substantially in parallel with a bottom surface of the packaging box. The cushioning member is held in the packaging box by engaging this engaging part with the relative cut and raised part.

In this structure, the cushioning members are held in predetermined positions in the packaging box. Therefore, the positions of the cushioning members are not shifted when a product to be packaged is placed in the packaging box, and the packaged product is not taken out with the cushioning members left attached thereinto. However, since the cut and raised parts are formed in the internal surface of the packaging box, the durability of the box lowers greatly, and there is the possibility that the box collapses during the transportation of the product. Although the material of the packaging box can be changed to a stronger one, the price of the packaging box increases, and the cost of the packaging material increases. Although the packaging box and cushioning members can be enlarged, the material cost increases, and, in addition, the transportation expenses increases since the packaging box being transported becomes bulky, to give rise to problems.

This packaging box has a structure for fixing a product by engaging the engaging parts of the cushioning members with the cut and raised parts of the packaging box. However, since the same engaging parts are provided on the front and rear sides of the cushioning members, there is the possibility that, when a product whose shapes of the left and right cushioning members are different, such as a television set is packaged, the cushioning members to be arranged on the left and right sides of the product be fixed to wrong sides thereof. Furthermore, since cut and raised parts are formed on the panel walls of the packaging box, through holes are formed thereon and the product and cushioning members contained in the box are seen from the outside therethrough, and accordingly, the external appearance of the product in a packaged condition is spoiled.

SUMMARY OF THE INVENTION

Therefore, an object of the present invention is to provide a packaging material capable of preventing positional shift of cushioning members when electrical equipment and the like is inserted in the packaging box without causing a lowering of the strength and durability of a packaging box; and, moreover, improving a cushioning effect for a packaged object such as electrical equipment without causing a cost increase.

A packaging material according to the present invention includes a packaging box and cushioning members, a bottom panel and a covering panel of the packaging box are made of inwardly bendable inner flaps and outer flaps respectively, each of the inner flaps being provided with at least a through hole, the cushioning members being provided in inner surfaces thereof with recesses with which corner portions or side portions of an object to be packaged are fitted, and on outer surfaces thereof with cushioning projections fitted in the through holes of the inner flaps, the length of the cushioning projections being set larger than the thickness of the inner flaps to thereby form a clearance between the inner flaps and the portions of the cushioning members which are other than the cushioning projections when the cushioning members are housed in the packaging box.

When the object product is inserted in the packaging material of such a structure, the corner portions or side portions of the object product are covered with the recesses of the cushioning members, and the cushioning projections of the cushioning members are fitted in the through holes of the inner flaps. Therefore, the cushioning members are fixed in the packaging box without causing positional shifts. An impact imparted to the packaging box is absorbed in the cushioning members fixed between the packaging box and packaged product, and the weight of the packaged product imparted to the inner surfaces of the recesses of the cushioning members is supported on the downwardly extending cushioning projections.

The packaging box is preferably made of corrugated board from the viewpoint of the elasticity and cost, and the cushioning members are made of expanded polystyrene that satisfies the requirements for the high strength and small weight.

When the size of the cushioning projections provided on the cushioning members is set slightly larger than that of the through holes of the inner flaps, the projections become difficult to be disengaged from the through holes. This enables to prevent more reliably the positional shift of the cushioning members in the packaging box, and, when the packaged product is taken out from the packaging box, the cushioning members are not fixed thereto and do not come out with the packaged product.

The through holes of the inner flaps and the cushioning projections of the cushioning members may be formed into shapes by which the longitudinal direction can be recognized, so that an error of fixing the cushioning members to the object to be packaged can be prevented. Moreover, when a plurality of cushioning projections are provided on upper and lower surfaces of the cushioning members, the longitudinal direction can be recognized, and it becomes possible to support the object product more stably.

This packaging material is suitable to be used for electrical equipment formed by combining electronic parts and precision mechanical parts together, and easily affected by an impact. It is preferable for securing a stable object-supporting force that the positions of the cushioning projections of the cushioning members be set correspondingly to that of the center of gravity of the object product. In the case of, for example, a television set, it is preferable to form the cushioning projections of the cushioning members in upper and lower positions on a cathode-ray tube since the cathode-ray tube accounts for the greater part of the weight of the product.

According to the packaging material of the present invention, the projections of the cushioning members are engaged with the through holes formed in the inner flaps of the packaging box. Therefore, the cushioning members may not cause positional shift, so that the object product contained in the packaging box becomes stable.

Since the size of the cushioning projections provided on the cushioning members is set slightly larger than that of the through holes of the inner flaps, the cushioning members are not lifted simultaneously with the product when the product is taken out of the packaging box.

Since the through holes are formed in only the inner flaps, the strength of the packaging box does not lower, and the through holes of the inner flaps are not seen from the outside, so that the external appearance of the packaging box is not spoiled.

The cushioning projections are formed in the position of the center of gravity of the product with clearances formed between the packaging box and the portions of the cushioning members other than the cushioning projections. Therefore, an impact imparted to the packaged product being transported is effectively absorbed. Accordingly, the product is not damaged during the transportation thereof, and the reliability of the transportation of the product is improved. Since the cushioning projections are fitted in the through holes provided in the inner flaps, the portions capable of cushioning the product increase by a level corresponding to the thickness of each of the inner flaps. Therefore, even when the clearances provided between the cushioning members and packaging box are narrowed, a cushioning effect can be obtained, and in its turn the cushioning members can be miniaturized. This enables a decrease in the cost due to the reduction of the materials.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a perspective view showing a first embodiment of the packaging material according to the present invention and a television set, an object to be packaged;

FIG. 2 is a perspective view showing cushioning members and the television set;

FIG. 3 is a longitudinal sectional view showing the interior of a packaging box containing the television set therein with a front panel of the packaging box removed;

FIG. 4 is a sectioned front elevation showing the interior of the packaging box containing the television set therein with cushioning projections of the cushioning members shown in longitudinal section;

FIG. 5 is a sectioned side elevation showing the interior of the packaging box containing the television set therein with the cushioning projections of the cushioning members shown in longitudinal section;

FIG. 6 is an enlarged partial sectional view in side elevation showing the portion of a lower cushioning member fitted in a through hole of the packaging box;

FIGS. 7A and 7B are a side view and a plan view respectively showing an upper cushioning member;

FIG. 8 is a partial enlarged plan view showing a through hole formed in an inner flap;

FIG. 9 is a perspective view showing a second embodiment of the packaging material according to the present invention and a disk apparatus as an object to be packaged;

FIG. 10 is a perspective view showing the condition of the disk apparatus to be placed in the packaging box with cushioning members fixed to both side portions of the disk apparatus; and

FIG. 11 is a perspective view showing a third embodiment of the packaging material according to the present invention and a disk apparatus as an object to be packaged.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT

FIGS. 1 to 8 show a first embodiment of the packaging material according to the present invention, which includes a packaging box 1 made of a corrugated board, and cushioning members 10, 10 and 11, 11 made of expanded polystyrene, and which is formed so as to package a television set TV. The packaging box 1 is formed rectangular of a front panel 2 constituting a front wall, a rear panel 3, left and right side panels 4, 4, bottom side front and rear outer flaps 5, 5 constituting a bottom panel, bottom side left and right inner flaps 6, 6, cover side front and rear outer flaps 7, 7 and cover side left and right inner flaps 8, 8. The bottom side left and right inner flaps 6, 6 and cover side left and right inner flaps 8, 8 are provided with through holes 6 a, 6 a, 8 a, 8 a in which parts of the cushioning members are fitted. After the bottom side left and right inner flaps 6, 6 are folded, the bottom side front and rear outer flaps 5, 5 are folded to form the bottom panel. Therefore, the through holes 6 a, 6 a appear in the bottom panel but enclosed with the bottom side front and rear outer flaps 5, 5, so that these through holes are not seen from the outside.

The cushioning members used include lower side cushioning members 10, 10 covering left and right corner portions of a lower side of the television set TV, and upper side cushioning members 11, 11 covering left and right corner portions of an upper side thereof. Each lower side cushioning member 10 is provided at an upper side thereof with a recess 10 a to cover a lower corner portion of the television set TV of a right angled shape, and at a lower side thereof with a cushioning projection 10 b to be fitted in the through hole 6 a formed in the bottom panel side inner flap 6 of the packaging box 1. On the other hand, each upper cushioning member 11 is provided at a lower side thereof with a recess 11 a covering an upper corner portion of the television set TV, and at an upper side thereof with a cushioning projection 11 b to be fitted in the through hole 8 a formed in the cover side inner flap 8 of the packaging box 1.

In order to contain the television set TV in the packaging box 1, the television set TV with the cushioning members 10, 10, 11, 11 fixed to the corner portions thereof is placed in the packaging box 1 (refer to FIG. 1). The packaging of the television set TV may also be done by arranging the cushioning members 10, 10 on a bottom surface of the packaging box 1 without fixing the cushioning members 10, 10, 11, 11 in advance to the corner portions of the television set TV, inserting the resultant television set TV in the packaging box 1, and dosing the cover of the packaging box 1 with the cushioning members 11, 11 fixed to upper left and right corner portions of the television set TV. In order to close the cover for the packaging box 1 after the television set TV is inserted therein, the inner flaps 8, 8 are folded first, and thereafter the outer flaps 7, 7. As a result, the television set TV comes to be packaged with the cushioning projections 11 b of the cushioning members 11 fitted in the through holes 8 a of the cover inner flaps 8.

FIG. 3 shows the interior of the packaging box 1 in which the television set TV is housed with the front panel 2 removed. The cushioning members 10, 10, 11, 11 fixed to the lower left and right corner portions and the upper left and right corner portions of the television set TV are in contact with the corner portions of the packaging box 1 and housed therein. In such packaged condition, a space S is formed between the television set TV and the packaging box 1, and an impact imparted to the packaging box 1 during the transportation of the television set TV is absorbed in the cushioning members 10, 10, 11, 11, the television set TV being thereby protected. The weight of the television set TV exerted on inner surfaces of the recesses 10 a, 10 a is borne by the downwardly extending cushioning projections 10 b, 10 b.

FIG. 4 shows the interior of the packaging box 1 in which the television set TV is housed with the cushioning projections 10 b, 11 b taken in longitudinal section, in which the cushioning projections 10 b, 11 b of the cushioning members 10, 11 fixed to the upper and lower, left and right corner portions of the television set TV are fitted in the through holes 6 a, 8 a formed in the bottom side and cover side inner flaps 6, 8 of the packaging box 1. Therefore, the cushioning members 10, 11 do not cause positional shift in the packaging box 1, and the television set TV can be supported stably in a fixed position.

FIG. 5 shows the condition of the television set TV supported on the cushioning members 10, 11 in the interior of the packaging box 1 from the side viewpoint. Each lower corner portion of the television set TV is fitted in the recess 10 a of the relative cushioning member 10, and each upper corner portion thereof in the recess 11 a of the relative cushioning member 11. The cushioning projections 10 b, 11 b of the cushioning members 10, 11 are fitted in the through holes 6 a, 8 a formed in the relative inner flaps 6, 8. The cushioning projections 10 b, 11 b of the cushioning members 10, 11 are provided in the positions corresponding to the center of gravity of the television set TV. Namely, since the center of gravity of the television set TV is positioned correspondingly to the heavy cathode-ray tube thereof, the cushioning projections 10 b, 11 b are provided in upper and lower positions on the cathode-ray tube, thereby effectively absorbing an impact imparted to the packaging box.

As shown on an enlarged scale in FIG. 6, the cushioning projection 10 b is fitted in the through hole 6 a formed in the lower inner flap 6. The length of a projecting portion of the cushioning projection 10 b is set larger than the thickness of the inner flap 6, thereby forming a space S1 between the portion of the cushioning member 10 other than the cushioning projection 10 b and the inner flap 6. Even when an impact is imparted to the television set TV to cause the cushioning projection 10 b to be compression deformed, the portion of the cushioning member 10 other than the cushioning projection 10 b does not impinge upon the inner flap 6 owing to the existence of the clearance S1, and the television set TV is thereby protected. The cushioning member 11 fixed to the upper corners of the television set TV is also formed in the same manner (refer to FIG. 5).

A size a×b of a rectangular plane of the cushioning projection 11 b of the cushioning member 11 and that c×d of the through hole 8 a formed correspondingly in the inner flap 8 have relation of a≧c, b≦d (refer to FIGS. 7B and 8). Therefore, the cushioning projection 11 b is fitted in the through hole 8 a without a clearance therebetween, and rather in such a manner that the cushioning projection 11 b expands the through hole 8 a, and the cushioning projection 13 fitted in the through hole 8 a thereby becomes difficult to disengage therefrom. This relation also applies to the structure of a combination of the cushioning projection 10 b of the cushioning member 10 and the through hole 6 a formed in the inner flap 6.

FIGS. 9 to 10 show a second embodiment of the packaging material according to the present invention, which includes a packaging box 20 of corrugated board, and cushioning members 30, 30 of expanded polystyrene, and which is formed for packaging a disk apparatus DR The packaging box 20 is formed to a shape substantially similar to that of the rectangular disk apparatus DP, and a bottom panel and a cover panel have bottom side left and right inner flaps 21, 21 and outer flaps 22, 22, and cover side left and right inner flaps 23, 23 and outer flaps 24, 24. The bottom side and cover side inner flaps 21, 23 are provided with through holes 21 a, 23 a respectively.

The cushioning members 30, 30 are formed symmetrically, and provided in inner surfaces thereof with recesses 30 a, 30 a in which left and right portions of the disk apparatus DP are fitted. Each cushioning member 30 is provided on the portion of an upper surface thereof which corresponds to the through hole 23 a of the inner flap 23 with an upwardly extending cushioning projection 31, and on the portion of a lower surface thereof which corresponds to the through hole 21 a of the inner flap 21 with a downwardly extending cushioning projection 32. The through holes 21 a, 23 a and the cushioning projections 32, 31 are formed in the shape of an arrow indicative of a front direction, which indicates the direction in which the cushioning members are fixed to the disk apparatus DP.

The disk apparatus DP is placed in the packaging box 20 with the cushioning members 30, 30 fitted around both side portions thereof (refer to FIG. 10). In order to cover the packaging box 20 after the disk apparatus DP is placed therein, the inner flaps 23, 23 are folded first, and the outer flaps 24, 24 thereafter. When the disk apparatus DP is housed in the packaging box 20, the cushioning projections 32, 32 are fitted in the through holes 21 a, 21 a of the bottom side inner flaps 21, 21. When the cover is dosed, the cushioning projections 31, 31 are fitted in the same manner in the through holes 23 a, 23 a of the inner flaps 23, 23.

Since the shape of both side surfaces of the disk apparatus DP is rectangular, both side portions of the disk apparatus DP can be fitted in the rectangular recesses 30 a of the cushioning members 30 even when the longitudinal direction in which the disk apparatus DP faces is erroneous. However, when the center of gravity of the disk apparatus DP does not exist in the center of the cushioning member, the cushioning projections 31, 32 extending downward and upward from each cushioning member 30 is provided not on the center of the cushioning member but on the portions thereof which are offset in the longitudinal direction from the center thereof in accordance with the mentioned center of gravity. Therefore, the shape of the cushioning projections 30, 31 and inner flaps 21, 23 can be changed to that of an arrow as mentioned above, so as not to mistake the direction in which the cushioning members face when the cushioning members are fixed to both side portions of the disk apparatus DP.

The length of the lower side cushioning projections 32 and upper side cushioning projections 31 are set larger than the thickness of the inner flaps 21, 23 to form clearances adjacent to these cushioning projections. An impact imparted to the disk apparatus DP can be absorbed owing to the compression deformation of the cushioning projections 31, 32.

FIG. 11 shows a third embodiment of the packaging material according to the present invention. This embodiment is formed by adding cushioning projections 31 a, 32 a having a square shape in plan to the upper and lower surfaces of such cushioning members as are provided in the second embodiment, and forming through holes 23 b, 21 b in which the cushioning projections 31 a, 32 a are fitted, in the corresponding portions of the upper and lower flaps. Since two cushioning projections 31, 31 a and 32, 32 a are thus provided on the upper and lower surfaces respectively of the cushioning member 30 a, a disk apparatus DP housed in a packaging box 20 a is more stabilized, and an impact imparted to the disk apparatus DP is efficiently absorbed. Also, the positioning and fixing of the cushioning member 30 a can be done without an error. 

1. A packaging material comprising a packaging box and cushioning members, a bottom panel and a cover panel of the packaging box being made of inwardly bendable inner flaps and outer flaps respectively, each of the inner flaps being provided with at least a through hole, the cushioning members being provided in inner side surfaces thereof with recesses in which corner portions or side portions of an object to be packaged are fitted, and on outer side surfaces thereof with cushioning projections fitted in the through holes of the inner flaps, the length of the cushioning projections being set larger than the thickness of the inner flaps, whereby a clearance is formed between the inner flaps and the portions of the cushioning members which are other than the cushioning projections when the cushioning members are housed in the packaging box.
 2. A packaging material according to claim 1, wherein the packaging box is made of a corrugated board, the cushioning members being made of expanded polystyrene.
 3. A packaging material according to claim 1, wherein the size of the cushioning projections is set slightly larger than that of the through holes of the inner flaps.
 4. A packaging material according to claim 1, wherein shape of the through holes of the inner flaps and that of the cushioning projections of the cushioning members are set so that recognition of the longitudinal direction can be made.
 5. A packaging material according to claim 1, wherein the cushioning members are provided on the upper and lower surfaces thereof with a plurality of cushioning projections respectively.
 6. A packaging material according to claim 1, wherein the object to be packaged is electrical equipment.
 7. A packaging material according to claim 1, wherein positions of the cushioning projections are set correspondingly to that of the center of gravity of the object to be packaged. 